Manufacture of rubber composition flooring



Feb. 26, 1929.

J. B. LOSEY ET AL MANUFACTURE OF RUBBER COMPOSITION FLOORING 2Sheets-Sheet w Hm X l i w c 7////%//////// -////////W//// 7/%//////// IF,eb. 26, 1929. I 1,703,312

J. B. LOSEY ET AL MANUFACTURE OF RUBBER COMPOSITION FLOORING FiledNovl1925 2 Sheets-Sheet 2 I mm! II Elfin/55 By 14W /7 TOR/VL'VS Cit PatentedFeb. 26, 1929.

UNITED STATES rATENr OFFICE.

JOHN B. LOSEY AND WALTER It. STONE, OF SYRACUSE, NEW YORK.

MANUFACTURE OF RUBBER COMPOSITION FLOORING.

Application filed November 3, 1925. Serial No. 66,517.

This invention relates to the manufacture of rubber compositionflooring, wainscotmg and analogous articles.

The main object is to provide a simple, economical and eitficient methodof producing articles of this character from flat pieces of rubbercomposition material applied to each other face to face under heat andpressure suliicient to form a homogenized article.

Another object is to make the surface sections of relatively small areaas compared with the base section and, if desired, of different colorsso as to perniit the formation of varying designs in the individual orassembled articles.

A further object is to mold the entire unit with a tongue and groove inopposite edges thereof in one and the same operation.

Another object is to form each unit with a relatively soft pliable baseand relatively harder surface sections and to leave the surface sectionsuna tached to each other to compensate for slight expansion andcontraction and enable the flooring to conform more readily to unevensupportmg surfaces.

Other objects and uses will be brought out in the following description.

In the drawings Figure 1 is a transverse vertical sectional yiew of amold with a section of flooring formed therein, together with portionsof the lower and upper heated pressing elements for forcing the sectionsof the mold into pressing co-action upon the article.

Figure 2 is a longitudinal sectional view, partly broken away, of thedetached mold with a section of flooring therein.

Figure 3 is a perspective View, on'a reduced scale, of a section offlooring made under my improved apparatus and process.

l igures a, 6, '2' and 8 are perspective views, on a reduced. scale, ofthe upper section of the mold, the reinforcing fabric, therubber-eomposition sheet forming the base of the flooring, therubber-composition plates to be applied to one of the surfaces of thesheet, and the lower section of the mold respectively, the ends of thesheet in Figure 6 being broken away.

The apparatus shown in the drawings for carrying out the pr cess andproduct comprises lower and upper mold sections -1-- and -2-, oppositelengthwise insert sections -3 and 4L and corresponding end insertsections 3 and l., all of which are constructed and assembled in suchmanner as to form in one operation a complete strip of flooring of thedesired length, Width and thickness with a tongue and groove alongopposite lengthwise edges and also along the opposite end edges, saidapparatus also in eluding lower and upper pressing elements 5 and 6which are provided with chambers 5 and -6- for receiving steam or otherheating agent whereby the dies and article under formation between themwill be subjected to heat and pressure at one and the same time.

The dies or mold sections 1 and 2 are preferably rectangular and ofsomewhat greater length and width than the article to be formed betweenthem so as to form rigid marginal walls around the chamber in which saidarticleis formed for receiving the insert sections 3 and 4l and 3 and'4-, said mold sections being preferably lengthwise die sections 3 and land is also provided with transverse grooves -7 near the ends thereoffor receiving the die sections 3 and -4'. The grooves 7- and 7 are ofless depth than the thickness of their corresponding die sections 3 andlwhich when seated in their respective grooves project beyond the uppersurface of the section -1 and form an upwardly projecting marginal ribalong the sides and ends of the last-named section with the upper faceof the ribs disposed in substantially the same horizontal plane parallelwith the bottom surface of the section 1. i

These ribs or dies sections --3 and 4.- -3 and 4 are provided in theirupper sides with lengthwise grooves 15 communicating with each other atthe corners and extending to the exterior sides and ends of the ribs toform clearance channels for the reception of excess stock which may bepressed from the article during its formation under heat and pressure bythe pressing'ele- 'b-' Figure 7, which are arranged end to end insaidchamber.

The bottom wall (it the chamber 10 is provided with a series orrelatively thin and shallow transverse ribs or spacing members 11arranged in uniformly spaced relation longitudinally and correspondingto the lengths of the rubber composition plates which are adn pted to beplaced between them. Thatis, the ribs '11 a nd side and end walls of thechamber 10-;'rorm a seizes oi? square pockets, each receiving); one ofthe rubber conithis'instance are square and of approximately the samethickness the depth of the ribs or pockets formed th'ereb althrnig ghiii-practice the ribs may be of Sll tly lcSS'tltlptli than the thicknessof the plates so as to assure proper vulcani'zing or the ends of theplates to the overlying rubber composition sheet.

These ribs serve to prevent the vulcanization of the meeting edges ofthe plates to the rubber composition sheet while the various layers ofthe flooring are being pressed together under heat so'that when theflooring is completed the meeting ends oi the plates which were slightlyseparated by the ribs ll during the vulcanizinp operation will whenthefl oorin is completed and removed from the dies, ibstan' lly closeunder the inherent elasticitv of the material to form a smooth surfaceand at the same time preserve adefinite amount of flexibility of theflooring to enable 1t to conierm more readily to uneven surfaces of theunderlyin floor bed.

r i i 7 l v i 7 These plates o and ?2 are adapted 'to be assembled uponone face ot a rubber composition strip "12 of approximately the samelength and width as the chamber l() in the die l-, the thickness of thestrip being approximately equal to or slightly greater thanthn t of theplates or oi? sailicu lllthickness to permit thi mention of tongues andgrooves in the ma 7 the completed flooring in a m described.

- A layer ll of wire fabric of substanttially the same surfacednnenslons as the and is provided in its underside with a centrallengthwise chamber "14 of approximately the same dimensions as thechamber 10 with which it is adapted to'r'egisterwhen the mold sectionsare assembled for use.

The upper wall of the chamber 1 l is substantially flat and togetherwith the bottom wall of the chamber 10- determines the thickness of thefloofing when completed said upper die 2- being also provided in itsunderside with a marginal grooves l' surro undingthe chamber -1 l-- andregister ing with the grooves -15 in the die sections -3 and l and 7'0and l' for receiving excess material which may be discharo'ed from thechambers '10- and 1' l during the formation of the flooring with thedies, V

One of the len hwise die sections as 3 and one of the end dies as 3' areprovided with il'iwardly projecting ribs 16- in the same horizontal.plane and approximately midway between the bottom wall of the chamber'-1U and top wall of the chamber l to term grooves -g in thecorresponding edges of the completed flooring VF-.

The other lengthwise die section -tand also the remaining end sections4- are provided along their inner edges with lengthwise grooves 17cooperating with opposed grooves l'. in the adjacent lengthwise and endwalls of the die section 2 to form suitable tongue gon the ren'iaininglengthwise edge and end edge oi the completed flooring strip F-, thespace between'the lower and upper walls of the grooves 17 and -17 beingdisposed in substantially the same horizontal plane as the rib l6r onthe die sections 3- and 4 to assure the proper matching of the flooringstrips when assembled edge to or e or end to end.

previously statedfwhen the die sections assembled in their respectivegrooves in the die section -l-:they project slightly above the uppersurface of said die section "1- and thereby iormj w h the last-nanieddie sec on marginal rabbets -18while the lower side of the r oer diesection -E'3--- is formed w th con" -19 extending); alon its op wise andend edges 2' hown in The portions ot the lengt e lengthre fie lures nalflanges h) re iterinp; with the end d c rtions -23 and ''-liare cut-awayat to receive the ad aw oortions oi the or l sections 3 a? when the diesections -1- and 2'- are brought into press k action upon the interposedflooring material, 1 l i f V The central portions of the end flangesarea-lilo cut away to :torrn openings n1- communicating" with theadjacent end grooves -15- to permit the expulsion therethru. of excessmaterial which may be expolled from the rubber composition material ofthe flooring strip during the vulcanizing process. I

Process.

Assuming that the rubber composition sheet *-12- has been previously m eto toe desired length, width and thiclii ss corresponding to the lengthWidth and depth oi the chambers -40 and -l l ot the mold and that theplates 7) and have been ineriously cut to the desired term and sizecorresponding to the form and size of the pockets between the ribs ll.the die section -l.- with its insert sections --3 and a and -Z3' and -:lthereon is placed preferably in a horizontal. position upon a suitablesupport with the open side of the chamber -l O uppermost.

The plates -Z and Z are then plac d in too pockets between the ribs 1lin the chamber --luntil all the poclt in said chamber are lilie theplates of (hi-- iicrent colors, when difi'erent colors are beingalternately placed.

The sheet l2 is then placed tlatwise upon the upper faces ot the platesZ)- and so that its marginal edges will abut against inne' edges of thedie sections 3 and and 3 and l-+ or in exact registration with thechamber l().

The Wire fabric reinforcing strip which is of slightly less ar a thanthe area of the chambers --10- and 1-il and also of slightly less areathan the surface area of the sheet 12 is then placed upon the uppersurface of said sheet Within the marginal edges thereof, the object ofthe slightly re dnccd area of the reinforcing fabric being to preventthe projection of the edges thereoi beyond the corrcspon ding edges otthe flooring strip when the latter is completed and also to enable saidreinforcement to be imbedded and concealed entirely Within the sheet l2when the tlooring strip is completed.

hen the reinforcing fabric is properly 1L Ann 'placed on the strip --12-the die section -2- is placed in operative position upon the die section-lso that the flanges l will register with the rabhets ltl-- to hold thedie sections against relative ondwise or lateral movement. Thiscompletes the ton mat-ion oi. the mold with the stock therein forforming the flooring the mold being then inserted between the pressingelements 5- and 6 one at least of which is operated by hydraulicpressure in any Well-known manner commonly known in the use of hydraulicpresses capable of subjecting the dies to many tens pressure and as hemovable pressing element is operated to ell-eat such pressure they aresimultaneously heated by the admission of steam or other heating agentto the chambers 5 and 6--, said heatbeing transferred to the dies 1- and2 also S and 4land 3 and 4. Which in turn impart their heatto thevarious elements of the flooring composition.

This sin'iultaneous application of pressure and heat to the assembledparts of the flooring, causes the softening of the rubber compositionelement sutlicient-ly to expand the edges thereo'l. against the side andend walls (1-1 the chambers E and 10 and to form tongues and grooves inand upon the marginal edges of the flooring as previously described.

This pressure and heat a plied to the flooringcomposition also causesthe vulcanization of the plates Z) and -bto the adjacent surface of thesheet l2' and at the same time owing to the pliability .ot the rubbercomposition of the sheet 12- and the unpliability of the wirereinforcement -13 the latter will 7 become imbedded and entirelyconcealed Within the adjacent surface of said sheet thereby becoming apermm nt part 01 the flooring strip.

l will be evident from the foregoing description that the Wirereinforcing fabric may be entirely eliminated and that the form or sizeof the surface plates and base may be varied at will Withoutdepaitiiugfrom the spirit of the invention which contemplates broadlythe formation of a flooring trom a plurality of layers of rubbercomposition with tongues and grooves therein in a single operation andin such manner than when completed constitutes a homogeneous Whole byincorporating the contiguous faces of the parts one into the other insuch manner as to obliterate structural joints.

It is also evident that in the use of rubber composition plates upon abase o'lf similar composition the coloring or ornamentation of theseveral plates upon the same base 'may be widely varied thus permittingthe forma tion of dilierent letters or characters or designs in theassembly of the flooring strips upon a floor or other supportingsurface. Reference is hereby had to our pending divisional applicationsSerial Nos. 169 891 and 169 892, both filed February 21, 1927.

I claim 2-- 1. The herein described method of making laminated flooringconsisting in applying a series oi square plat-es of rubber compositionto the upper surface of a fiat strip ol? rub ber composition separatingthe adjacent edges of the plates during vulcanization, vulcanizing theplates to the strip and removing the separating means aftervulcanization.

2. The herein described method of making laminated flooring consistingin applying a series of similar plates or rubber composition ed 'e toedge along and upon one of the surfaces of a flat strip of rubbercomposition,

applying a metal reinitorcing layer to the other surface of said strip,subjecting the as V sembled parts to pressure and heat suificicnt tovulcanize the plates to the strip and to embed the reinforcing layerentirely within the adjacent surface of the strip, and holding theadjacent edges or the plates against contact- With each other during:the or ssing and heating operations.

3. The herein described method oi": making laminated flooring comprisingthe melding of a flat strip of lj'lliiliifil' composition oi? uniformthickness, applying aseries of: rubber com osition plates to one surfaceof the strip, placing separators between the adjacent edg; s of thepiates, Vlil(i\11l7jll1,f the plates to the strip while the separatorsare in place d removinp the separators after vulcanization.

4. helieroin described method oi making laminated flooring comprisingthe melding of a fiatrubber composi i strip oi? uniform thickness and ofsubstantially uniform Width from end to end, app yingr a series ofrubber composition plates to one surface O'i' the p, insertingseparators between the adjacent edges of the plates, vulcanizing theplate to the strip While the separators, and rciuc ring? the separatorsafter valcani 1' 5. The herein described method of mai laminatedflooring comprising the moldi of a fiat strip of rubber composition ofform thickness, applying a series of rubber composition plates of aboutthe same width as the strip to one surface of the strip so thatcorresponding. edges of the plates and strip will coincide, placingseparators between the adjacent edges of the plates, Vulcanizing theplates to the strip While the separators are in place, mohling a tongueand a groove in opposite edges of the laminated body duringvulcanization, and removing the separators after viiilcai'iization.

I 6. The herein described method oi making laminated floor-incon'iprising molding a flat rubber compositir strip into rectangularform oi uniform thickness and uniform; Width from end to end, applying aseries oi rubl or composition plates to one surface of the strip so thattheir adjacent edges Will be slightly separated one from the other,subjecting the plates and strip to vulcanizing pressure and heat,forming a tongue and a groove in 0pedgcs of the laminated body, by saidre and heat, holding the adjacent edges v platesin separated relationduring the vulcanising oi? the plates to the strip, and removing theholding means after vulcanization.

in witness whereof we have hereunto set our hands this 28th day ofSeptember, 1925.

JOHN B. LOSEY. V lVALTER R. STONE.

